EV battery Archives

BF1000 and BF2000 in EV Battery Enclosures: Sealing for Safety and Performance

Posted on July 2, 2025 by RobSEO

With the rapid acceleration of the Electric Vehicle (EV) market, we have seen an unprecedented focus on battery technology. At the heart of every EV lies its battery pack, a complex and highly sensitive component that demands robust protection. Ensuring the safety, performance, and longevity of EV batteries relies heavily on effective sealing and cushioning within their enclosures. This is where advanced materials like BISCO® BF1000 and BF2000 silicone foams play a critical, often unseen, role.

With our extensive expertise in high-performance rubber and plastics, and our manufacturing capabilities, at CB Frost, we frequently integrate BISCO® silicone foams into EV battery components.

The demanding environment of EV battery enclosures

EV battery enclosures are subjected to a unique combination of stresses:

Vibration and Shock: Constant road vibrations and potential impacts demand materials that can absorb energy whilst maintaining structural integrity.
Temperature Extremes: Batteries generate heat during operation and face varying external temperatures, requiring materials that perform reliably across a wide range of temperatures.
Moisture and Contaminants: Protection against water, dust, and other environmental contaminants is paramount to prevent short circuits and degradation.
Thermal Runaway Prevention: In the unlikely event of thermal runaway (a rapid, uncontrolled increase in temperature within a battery cell), the enclosure must contain the event and prevent its spread.
Electromagnetic Interference (EMI): Sealing solutions may also need to offer EMI shielding to protect sensitive electronics.

Traditional sealing materials often struggle to meet all these stringent requirements simultaneously. This is where the advanced properties of BISCO® BF1000 silicone and BF2000 foams excel.

BF1000 Silicone Foam: Precision sealing and cushioning

BF1000 silicone foam is a highly versatile, soft, and compressible silicone foam known for its excellent long-term sealing capabilities. Within EV battery enclosures, BF1000 silicone is often chosen for:

Battery housing seals: Its fine cell structure and excellent compression set resistance allow it to create reliable seals against ingress of dust and moisture, protecting sensitive battery cells and electronics.
Anti vibration and cushioning pads: Its soft, conformable nature makes BF1000 foam ideal for cushioning individual battery cells or modules, absorbing vibrations and shocks that could otherwise damage components.
Gap filling: Its ability to compress easily and fill irregular gaps ensures a consistent seal and support structure.
Thermal runaway protection pads: Silicone foams have good thermal stability, contributing to the overall thermal management strategy of the battery pack.

BF2000 Silicone Foam: The choice for extreme performance

Building on the strengths of the BISCO® silicone foam family, BF2000 takes performance to the next level. While sharing the excellent environmental resistance of BF1000, BF2000 offers:

Enhanced compression set resistance: Even under prolonged compression and various temperatures, BF2000 foam maintains its original thickness and sealing force better than many alternatives, ensuring long-term seal integrity. This is crucial for the extended lifespan expected of EV batteries.
Increased durability in harsh conditions: Its robust nature makes it exceptionally resilient in more demanding temperature cycles (-55℃ to +200℃) and under greater mechanical stress.
Superior shock absorption: For applications where impact protection is a primary concern, BF2000 silicone foam offers a higher degree of energy absorption.

These enhanced properties make BF2000 particularly valuable in critical sealing areas within the battery enclosure, especially where higher pressures, more extreme temperatures, or greater mechanical stresses are anticipated.

Why BF1000 and BF2000 are essential for EV batteries

Both cellular silicones contribute significantly to the safety and performance of EV battery enclosures by:

Preventing environmental ingress: Protecting sensitive battery cells from moisture, dust, and debris, which can lead to short circuits and premature degradation.
Vibration and shock mitigation: Extending the lifespan of battery components by absorbing mechanical stresses during vehicle operation.
Maintaining thermal stability: Their inherent thermal stability in extreme conditions supports overall temperature control within the enclosure.
Long-term reliability: Their excellent compression set resistance ensures seals remain effective over the electric vehicle’s lifespan, reducing maintenance needs and potential failures.
Flame retardancy: Many grades of BISCO® silicone foams offer inherent flame retardancy, complying with fire safety standards such as EN45545-2 and BS6853, adding an extra layer of safety within the battery enclosure.

The stringent requirements of EV battery technology demand materials that are truly at the forefront of innovation. BF1000 foam and BF2000 provide automotive engineers with reliable, high-performance sealing and cushioning solutions that are essential for the safe, efficient, and long-lasting operation of the next generation of electric vehicles.

If you’re designing or manufacturing EV battery enclosures and need expert advice on material selection, contact CB Frost & Co today.

How The Growth of the Electric Vehicles Market is Driving Demand for UK EV Battery Products

Posted on February 15, 2023November 5, 2024 by cbfrost_rubber_wp

Having entered into the EV battery market in 2022, CB Frost is on board to support the developing electric car industry as it grows over the next decade.

Whilst the balance of vehicles on the roads in the UK and Europe today is weighted considerably in the favour of traditionally fueled vehicles, as opposed to hybrid and electric vehicles, the demand for more environmentally friendly vehicles is growing fast. Whilst to date there has been a reliance on China for EV battery parts, as the market grows rapidly over the next decade, so too will demand for UK manufactured EV battery components.

Government commitments are playing a key role in the growth of the electric vehicles market. The EU has committed to phase out vehicles powered by combustion engines from the year 2035, whilst the UK government has pledged to ban the sale of any new petrol or diesel cars from 2030 onwards. Whilst these commitments are key to protecting the environment in the years to come, the growth of electric vehicles and reduction of traditional vehicle manufacture has raised concerns from UK MPs.

EV and HEV vehicles use Lithium-ion batteries, which are rechargeable and designed for a long life-span. Today, almost all of the processing of Lithium in the world takes place in China and east Asia, which has led to uneasiness from MPs that too much reliance on the east could lead to a break in the EV battery supply chain, should political tensions between Beijing and the west come to a head.

Lithium refinery projects are underway in Germany and France to help boost electric vehicle prospects in Europe, however, US President Joe Biden has attracted considerably green investment through his Inflation Reduction Act, which has put extra pressure on the United Kingdom and EU to up their renewable energy efforts.

Whilst Lithium is vital for electric vehicle batteries, Lithium-ion battery cells require specialist sealing and anti-vibration components to protect them and ensure their longevity. Partnering with Rogers’ Corporation and their range of specialist materials, CB Frost is well placed to deliver high-performance products to withstand the temperatures and compression that electric vehicle batteries are subjected to, protecting the interior battery cells.

UK battery components to extend EV battery life

As the UK and global vehicle market becomes more and more reliant on electricity, it’s vital that EV batteries are manufactured not only to provide sufficient power for their purpose, but also to withstand the pressures of day-to-day use and regular charging. In order for zero-emissions electric vehicles to flourish and reduce the need for fossil fuels, battery cells must have excellent longevity.

At CB Frost, we are dedicated to respecting the environment for a greener future and have the materials and manufacturing expertise to design and produce a range of high performance parts to protect Lithium-ion cells and extend EV battery life, including pressure management pads, battery housing seals, cooling plate spring pads, thermal runaway protection pads, manual service disconnect seals, anti vibration pads and cushioning pads.

Rogers’ Corporation’s PORON® polyurethanes and BISCO® silicone materials feature all key attributes required for keeping battery components in place and managing compression forces, vibration and fluctuating temperatures, along with providing a seal against dust, fluid and other external contaminants that could affect the lifespan of the battery cell:

Excellent fire retardancy qualities
Meeting all essential flammability requirements
Low outgassing
Thermal prorogation delay
Excellent compression set resistance.
Chemical resistance
Capacity fade reduction

Read more about our specialist Polyurethane and Silicone EV battery materials here.

To discuss our range of specialist EV materials and to learn more about the essential high-performance protective parts we can manufacture, call our team today on +44 (0)121 773 8494 or contact us here.

CB Frost in 2022: Electric Vehicles and More

Posted on January 5, 2023November 7, 2024 by cbfrost_rubber_wp

As we enter the new year, it provides an ideal opportunity to reflect on the events of the year that just passed. Whilst 2020 and 2021 saw us face certain restrictions as a result of COVID-19 as businesses in all industries continued to face the long term effects of the pandemic, 2022 was a year that saw CB Frost enter new markets such as electric vehicles, along with winning new contacts in existing markets.

Let’s look at some of what we achieved in 2022, along with some of the key topics we covered in our blog posts.

Entering the Electric Vehicles Market

With the number of electric (EV) and hybrid (HEV) vehicles on the road rapidly increasing, in 2022 we teamed up with Rogers’ Corporation to supply a range of products for Lithium-ion battery packs for EV and HEV vehicles. With access to Rogers’ range of specialist materials for EV batteries, combined with our expertise in manufacturing, we have been able to develop high performance products for applications including

Pressure management pads
Battery housing seals
Cooling plate spring pads
Manual service disconnect seals
Thermal runaway protection pads
Anti vibration and cushioning pads

With the return of trade shows and expos in a physical capacity, we were excited to showcase Rogers’ Corporation’s range of PORON® polyurethanes and BISCO® silicone materials, along with our range of EV battery components. Two key events we attended included the Battery tech Expo at Silverstone, and the Battery Cell and Systems, and Vehicle Electrification Expos at the NEC, Birmingham.

Attending these events provided our team with the chance to explore the scope of battery technology innovations, along with making new contacts and discussing our own range of materials and EV battery products.

Supporting the Ministry of Defence

CB Frost have long been a supplier to the Ministry of Defence, working alongside well-known names in the defence industry, including Babcock Defence, BAE and General Dynamics. In May 2022, we were pleased to sign a new £60k contract to supply the MoD.

Following more than 12 months of hard work by CB Frost Business Development Manager Daniel Brock and Sales Coordinator Charlotte Homer, we were awarded a long term contract from the MoD to support the British Army. Under our new contract, we supply a range of rubber products for the MoD’s UK armoured vehicle programme. The Boxer is a state-of-the-art armoured vehicle offering the highest levels of protection whilst maintaining fantastic mobility.

Our Material Range and Manufacturing Capabilities

As well as providing news on new developments for CB Frost and the industries that we supply, our blog also provides a platform to highlight our extensive range of high performance materials, designed to meet the requirements and regulations of many industries.

To help our customers in selecting the best suited materials for their applications, we discussed the key advantages of our range of foam rubber products, as well as taking a more detailed look at our high performance silicone materials for the rail industry, and highly versatile PORON® Urethane materials.

As experts in the conversion of rubber, sponge and plastic materials, in addition to providing our expertise in helping customers select the right materials for their needs, we also deliver the highest quality of manufacturing services, converting our impressive range of materials into products to meet the needs of our clients.

During 2022, we made the most of our website’s blog to highlight our manufacturing knowledge and experience, sharing our rubber moulding advice and why to choose injection or compression moulding. We also profiled our extrusion and fabrication capabilities, discussing the processes involved in rubber extrusion and fabrication processes.

Looking Forward to 2023 and Beyond

We believe that a key element contributing to our century plus existence as a company is our forward thinking approach. In addition to learning from the lessons offered by the challenges we have faced each year in the history of CB Frost, we always have our fingers on the pulse of each industry we supply and work tirelessly to not only keep up with industrial advancements, but understand how technologies and processes will continue to advance in the years to come.

To discuss your future needs and learn more about our extensive range of high performance materials and manufacturing capabilities, contact our team today by calling 0121 773 98494.

EV Battery Materials – Exploring the Electric Vehicles Market

Posted on June 8, 2022November 7, 2024 by cbfrost_rubber_wp

Having teamed up with Rogers’ Corporation and their range of PORON® polyurethanes and BISCO® silicone materials, CB Frost have entered the fast growing electric vehicles market, manufacturing and supplying a range of EV battery components, including battery compression pads and cushions, anti-vibration pads, enclosure seals, thermal runaway protection and impact protection pads.

In order to network with other organisations within the EV and HEV market and to grow our knowledge of battery technology, we have committed to several Electric vehicle and battery technology trade shows this year and we recently had the opportunity to attend the Battery Tech Expo at Silverstone, Northamptonshire.

Battery Tech Expo 2022

Battery Tech Expo is an annual event that brings together the most up to date technologies and services related to battery technology, from battery storage and battery management systems, to lithium ion batteries and EV/HEV batteries, with the aim of exploring the innovation driving the battery supply chain.

This event provided an excellent opportunity for us to learn more about the latest battery technology, how batteries are manufactured, how they are stored and how they are used in a wide variety of applications, including electric vehicles.

As well as a learning experience, the Battery Tech expo also allowed us to network with a wide range of other organisations within the battery supply chain. CB Frost Business Development Manager Daniel Brock commented:

“The Battery Tech Expo at Silverstone was a great experience. As well as exploring the full scope of battery technology innovations, we had the opportunity to discuss our own range of materials and manufacturing capabilities.

“We are very happy to have picked up 10 new prospects at the expo and even received an order whilst on site!”

Battery Cell and Systems Expo and Vehicle Electrification Expo, NEC, Birmingham, 29-30 June 2022

On the 29-30th June, CB Frost will have the opportunity to attend the Battery Cell and Systems Expo and the Vehicle Electrification Expo, both of which will be held at the NEC, Birmingham.

The Battery Cell and Systems Expo is the UK’s largest ever battery technology exhibition and conference, bringing together representatives from the entire battery manufacturing supply chain. As well as providing the chance to learn from world class speakers, companies from around the world will be using the show to demonstrate and launch their products, showcasing innovative new technologies.

Alongside the Battery Cell and Systems Expo is the Vehicle Electrification Expo, which will bring together the entire electric vehicles supply chain and present the latest technologies in EV/HEV batteries, along with solutions to improve electric vehicle performance, safety, efficiency and sustainability.

CB Frost Sales Director Mark Jones, and Business Development Manager Daniel Brock will both be at the NEC, taking the opportunity to learn more about emerging technologies within the electric vehicle and EV/HEV battery industries, as well as introducing our range of high performance materials for EV battery applications, including:

PORON® Polyurethane
EVExtend Polyurethane
HT800 Silicone Foam
BF1000 Silicone Foam
BF2000 Silicone Foam
ProCell Aluminium Foil

Specialist EV battery materials and common applications

If you are attending the Battery Cell and Systems Expo and Vehicle Electrification Expo at the NEC and would like to get in touch with us, or if you would like to find our more information on our specialist EV/HEV battery materials and applications, call our team on +44 (0)121 773 8494 or get in touch here.

CB Frost Enter the Electrical Vehicles Market

Posted on May 10, 2022November 7, 2024 by cbfrost_rubber_wp

At CB Frost, in keeping with our core values, as well as our commitment to moving with the times and embracing new technologies, we also maintain a dedication to respecting the environment at all times and working to give back to society. As a result, to remain as a market leader in our industry, we are always excited by opportunities to enter exciting new sectors that promote a greener, more environmentally friendly future. Working with Rogers’ Corporation, we are now supplying components for the electrical vehicles market.

Supplying EV Battery Components

We have enjoyed a partnership with Rogers’ Corporation for over 25 years now, converting their range of specialist silicone materials for applications within the Rail industry and other sectors, and we are now pleased to announce that we have team up to work with Rogers’ to offer a wide range of battery pad and cushion solutions for Electric and Hybrid Vehicles.

Whilst most vehicles on the road today continue to be powered by traditional fuels, electric (EV) and hybrid (HEV) vehicles are very much on the rise. Governments throughout the world are making commitments to increase the production of EVs to promote a greener future and lower emissions from personal transportation. In November 2020, the UK government announced steps to phase out the sales of new petrol and diesel vehicles by 2030, along with plans for investing in EV infrastructure, to increase production of and access to electric vehicles.

As demand for electric vehicles grows, so too does the need for the EV batteries that provide the power source (or fuel) for these zero emissions vehicles. For electric cars and vehicles to be successful in the long term, investments in EV batteries are essential to ensure that they provide necessary power and last for longer.

Lithium-ion battery packs are the go-to power sources for the electric vehicle industry. They feature an excellent power density and ensure efficient charging, however, despite these benefits, they have relatively short lifespans and degrade faster depending on the automotive environments they face. At CB Frost, we are here to provide the EV/HEV battery pads, cushions and seals to protect Lithium-ion battery packs and increase their efficiency and lifespan.

Working with Rogers’ Corporation, we supply a wide range of materials for EV batteries, including:

Poron Polyurethane
EVExtend Polyurethane
HT800 Silicone Foam
BF1000 Silicone Foam
BF2000 Silicone Foam
ProCell Aluminium Foil

Our range of materials offer important characteristics to improve the performance and increase the lifespan of EV batteries, including excellent compression set resistance, good chemical resistance, excellent fire retardancy (and meeting several flammability requirements), low outgassing, thermal prorogation delay and capacity fade reduction.

With our manufacturing capabilities and range of high performance materials, we are well equipped to supply products for common EV battery applications including:

Battery compression pads and cushions
Anti-vibration pads for vibration isolation
Battery enclosure sealing
Thermal runaway protection
Impact protection pads

For more information on our specialist EV materials and common applications, click here.

If you have questions about our catalogue of EV materials or wish to make an enquiry, call our expert team today on +44 (0)121 773 8494 or get in touch here.

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